MDC XH7.4 XPEDITION HAULER Owner's manual

Brand: MDC

Model: XH7.4 XPEDITION HAULER

Type: Owner's manual

XH7.4

Expedition Hauler

User Manual and Guide

2020 Model Shown

©Copyright Market Direct Campers & Caravans 2020

Read owner’s manual before using the equipment. Third party component manuals should be read in conjunction

with this manual. Maintenance guidelines must be met or exceeded, failing to meet these guidelines may result in

serious injury or death and property damage. Specifications may change without notice. Images are for

demonstration purposes only

 
1 
 
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Table of Contents 
INTRODUCTION ......................................................... 2 
Handover Video                                      Setup Video .......... 2 
Pack Down Video                                   Kitchen & Electrical2 
Awning Setup      Annex Setup ................................... 2 
Store Locations ................................................................ 3 
Contact Details ................................................................. 3 
ABOUT YOUR CAMPER ............................................. 4 
Specifications ................................................................... 4 
Bearings and Seals ........................................................... 5 
Charging Your Camper ..................................................... 5 
Driving.......................................................................... 5 
Solar Power .................................................................. 5 
Mains Power ................................................................ 5 
Hitch ................................................................................. 6 
How to Hitch your coupling ......................................... 6 
Coupling ....................................................................... 8 
Uncoupling ................................................................. 10 
Canvas Care .............................................................. 11 
Seasoning the Canvas .................................................... 11 
Protecting Seams and Screens ....................................... 11 
Zipper Care ..................................................................... 11 
Protecting from Mould .................................................. 11 
Setting up your Camper ............................................. 12 
Choosing a Spot to Set Up.............................................. 12 
Levelling Your Camper ................................................... 12 
Site Power ...................................................................... 12 
Pole Diagram .................................................................. 13 
Preparing for Bad Weather ............................................ 14 
Packing Away Your Camper ........................................... 14 
Storage & Care .......................................................... 15 
Long Term Storage ......................................................... 15 
Interior ........................................................................... 15 
Exterior........................................................................... 15 
Securing Your Camper.................................................... 15 
Torque Settings .............................................................. 16 
Wheel Nuts ................................................................ 16 
Hitch .......................................................................... 16 
Trailing Arm Pivot Bolts ............................................. 16 
Brakes and Handbrake - Electric .................................... 16 
Features ..................................................................... 16 
Operation .................................................................. 16 
Trailer Plug Wiring ..................................................... 18 
Hand Brake ................................................................ 18 
Adjuster ..................................................................... 18 
Correct Use of Your Electric Brakes ........................... 19 
Important Safety Notice ............................................ 19 
Brake Adjustment ...................................................... 19 
Brake Cleaning and Inspection .................................. 19 
Magnets ..................................................................... 20 
Shoes and Linings ...................................................... 20 
Wheels and Tyres ...................................................... 20 
Highway ......................................................................... 20 
Off Road ......................................................................... 20 
Suspension ................................................................. 21 
Shock Absorbers & Bushes ............................................ 21 
Corrosion Prevention ..................................................... 21 
Electrical Systems ...................................................... 22 
Chargers & Inverters ...................................................... 22 
Battery Care ................................................................... 22 
Control Panel ................................................................. 23 
Gas & Water Systems..................................................... 23 
Hot Water System .......................................................... 23 
Water Pumps ................................................................. 23 
Connecting the Gas ........................................................ 23 
Pre-Trip Checklist ....................................................... 24 
Useful Accessories ..................................................... 24 
Levelling Blocks .............................................................. 24 
Wheel Chocks ................................................................ 25 
Covers ............................................................................ 25 
Stone Protection ............................................................ 25 
Trouble Shooting ........................................................ 26 
Electrical ......................................................................... 26 
Water ............................................................................. 27 
Gas ................................................................................. 27 
Brakes ............................................................................ 28 
Handy Tips ................................................................. 29 
Driving Off Road ............................................................. 29 
Trip Planning .................................................................. 30 
Warranty Statement ................................................... 31 
Maintenance ............................................................... 32 
Maintenance Schedule .................................................. 33 
Supplier Contact Details ............................................. 40 

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INTRODUCTION

WARNING– Before using this product you should read this manual and those

manuals supplied by component manufacturers applicable to this product.

This manual is supplied as a reference to required maintenance of the product. Failure to

use and maintain the product in accordance with what is outlined in this manual may affect

your warranty.

Incorrect and/or insufficient maintenance may cause product failure resulting in property loss, damage

or injury or death. Maintenance intervals are guidance for normal use, extreme use may require shorter or

additional maintenance intervals.

Manual content does not imply. express or other any warranty, the owner should read the limited

warranty terms included in this booklet.

Before using this product, you should be certain your tow vehicle is suitably rated and equipped to tow the product

safely and legally. The trailer and vehicle pairing must we within the safe “Maximum Towing Capacity”, “Ball Weight

Capacity” and “Gross Combination Mass” as stated by the vehicle manufacturer.

Before using your camper view the following videos:

Handover Video Setup Video

Scan the code or go to https://youtu.be/lecXyi-otd0 Scan the code or go to https://youtu.be/0YGVxlKOy0g

Pack Down Video Kitchen & Electrical

Scan the code or go to https://youtu.be/wzwDH53ebAo Scan the code or go to https://youtu.be/Ft5IRAFqtHg

Awning Setup Annex Setup

Scan the code or go to https://youtu.be/72z5_nNtz1Y Scan the code or go to https://youtu.be/g9fsCBEahk0

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Store Locations

QUEENSLAND

Brisbane

3/711 Beaudesert Rd

Rocklea QLD 4107

Caboolture

4 Boeing Place

Caboolture QLD 4510

NEW SOUTH WALES

Sydney

178-180 Hume Hwy

Lansvale NSW 2166

Newcastle

Unit 1, 2364 Pacific Hwy

Heatherbrae NSW 2324

VICTORIA

Melbourne

126 Canterbury Rd

Kilsyth South VIC 3137

Campbellfield

1551 Sydney Rd

Campbellfield VIC 3061

Welshpool

18 Bellows St

Welshpool WA 6107

SOUTH AUSTRALIA

Adelaide

1246 South Rd

Clovelly Park SA 5042

Contact Details

NATIONAL TOLL FREE

WARRANTY HOTLINE

SPARE PARTS

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1300 494 494

1300 MDC CARE

1300 632 2273

1300 MDC PARTS

1300 632 72787

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ABOUT YOUR CAMPER

Specifications

LENGTH

7.4

TENT COLOUR

Khaki / Sand

HEIGHT (HIGHEST)

1.577m closed, 3.2m opened

DRAWBAR

150 x 50 x 4mm RHS

TOWBALL WEIGHT

360

TARE WEIGHT

Approx. 2140kg

ATM

3500kg

SIZE CLOSED

7,440 x 2,300 x 1,577mm

OPENED

7,440 x 2,300 x 3,240mm

STYLE

Toy hauler

SUSPENSION

3.5T LPX Tandem independent trailing arm suspension

WHEEL/TYRE INFO

Goodride radial M/T 265/75/16R (Toyota 6 stud pattern)

BRAKES

12” Electric brake system

GAS CYLINDERS

1 x 9kg gas cylinder holder

JERRY CANS

1 x 20L jerry can holders

KITCHEN CONSTRUCTION

Slide out stainless steel kitchen top and sink

WATER TANK

80L poly

TOILET

Included

JOCKEY WHEEL

10” Swing-up and lockable

STABILISER LEG

4 x heavy duty lockable and adjustable drop-down

LIGHTS

LED submersible tail lights and number-plate light

CHARGER

Redarc Battery Management System 1230

HITCH

DO35

TENT

Huge 22sqm of living space if tent and annex set up

Annex

Comes with removable walls, floors and draft skirts that are detachable with a zipper and/or Velcro

CANVAS

16oz Sherpa Close weave canvas with double stitching throughout

MATTRESS BED BASE SIZE

1.95m x 1.65m

POLES

Galvanized steel pole, dia19/22/25mm

WINDOWS

Mosquito & midge proof netting

*All weights do not include gas bottles, jerry cans, annex walls & roof.

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Bearings and Seals

Bearings are a consumable item should be removed, inspected and repacked with grease every 5,000km and

replaced every 10,000km as best practice. See maintenance schedule for guidance.

Bearing Number: Inner Bearing 25590

Cone: 25520

Outer Bearing: 25590

Cone: 25520

Seal: 55 x 85 x 12

Charging Your Camper

Charging the batteries can be done in 3 ways.

Driving

To charge your camper while driving you will require a 12v power source via a 50-amp Anderson plug near the towbar.

The Anderson plug input to the camper controlled by the Redarc BMS unit. You will need to have a 12 pin trailer

connection with accessory power to the #12 pin if your vehicle has an ECU controlled “smart alternator.”

Solar Power

There is a dedicated input via a 50-amp Anderson plug on the driver’s side. Always use an unregulated solar panel.

Mains Power

Charging from mains power can be done by connecting an extension lead direct to the Redarc BMS unit. Ensure

correct battery type and mode are selected. Your camper is fitted with AGM batteries. Consult the Redarc User

Manual.

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Hitch

How to Hitch your coupling

Here is a short guide on how to safely use your coupling to couple and uncouple the

trailer from the towing vehicle.

Make sure the handbrake is applied prior to coupling and uncoupling.

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Make sure the dust cap is securely connected to the bump cover. This is done by locating the rear lip on the dust cap

onto the groove of the bump cover and then pushing it in a downward motion until the dust cover is secure (there

should be a slight click when it has been assembled correctly) Test if the dust cover is connected to the bump cover by

applying a slight upward force to the dust cover, it shouldn’t separate.

This procedure should be applied if you are uncoupling or coupling up.

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Coupling

STEP 1

Push down the button (1) and push the locking mechanism back (2). When the locking mechanism (2) is all

the way back, release the button (1) locking the plate in place

STEP 2

Offer up the tow pin to the coupling making sure the tow pin cover is removed and there is no visible debris on

it. Locking plate should be in unlocked position as shown. Lower the coupling onto the tow pin.

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STEP 3

Make sure the tow pin is seated inside the universal and the tow pin top is sticking out of the locking

mechanism (see below). Press the button (1) to release the locking mechanism there will be an audible

locking noise at which point the mechanism will return to the initial position as shown in step 1. Verify the pin is

correctly through the mechanism and assemble the cap. If the cap will not fit check the locking mechanism is

in the correct locked orientation.

Detail view of pin through locking mechanism.

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Uncoupling

STEP 1

Push down the button 1 and push the locking mechanism back 2. When the locking mechanism is all the way

back release the button while holding the mechanism to ensure it does not spring back to the locked position.

STEP 2

Lift the coupling up off the tow pin.

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Canvas Care

Seasoning the Canvas

The process of seasoning your canvas before use is an important one but fortunately an easy process. This process is

best done on a warm sunny day with no rain expected.

• Set up your camper and annex with all doors and windows zipped up and closed

• Using your garden hose apply a light spray of water over all the external canvas areas. Wet out the canvas

without allowing water to pool in any section then allow to dry thoroughly.

• Repeat the process of wetting and allowing to try another 2 times.

• On the third wetting check for any leaks in the canvas particularly along the seams. If a seam is weeping water

through, allow the canvas to thoroughly dry then apply a wax stick along the area of the seam. This is done by

lightly rubbing the wax stick over the area. Once applied wet the canvas and check again. NOTE: It is not

unusual for seams that aren’t able to be seam sealed with tape to weep after seasoning. This is not a

reflection of canvas or workmanship but simply a characteristic of canvas tents. If the leak persists, contact

your MDC customer representative.

Protecting Seams and Screens

Seams: When erecting any canvas tent, it is vitally important that you don’t stress the canvas by overtightening when

adjusting the poles. The most common cause of damage to canvas is over tensioning. Adjusting the tent should give

the canvas good shape but the material should be relaxed. If you can see the stitching exposed in a seam, then the

canvas is under strain and the pole should be backed off.

Screens: Fly mesh screens are vulnerable to damage by poles rubbing against it. When packing up your camper it is

important to close windows with both inner and outer canvas zipped up thus protecting the mesh. Never leave door

screens rolled up when packing your camper as this can cause harsh creases and damage the screen. Mesh damage

by owner misuse is not a warranty issue.

Zipper Care

Few parts of your camper work as hard as zippers particularly if you have young children. To get the maximum service

life from zippers there are precautions and maintenance you can do.

Never force a zipper. If it jams or becomes difficult back it up and start again ensuring the two rows are feeding evenly

into the slide without one row having much greater weight of canvas than the other. Avoid having doors half zipped

when the tent is in use. Leaving the slide in a poor position while the door canvas flaps around or people access the

door pushing the canvas out of the way can loosen and damage the teeth. Always fully open or close the entry doors

on your tent.

Dry lubricant spray is a great way to make zipping up your tent easier. Apply a light coating of dry lubricant along the

length of the zipper as needed.

Protecting from Mould

Mould is very difficult to clean once a tent is affected.

There are several ways you can prevent the

occurrence of mould on your canvas.

Never leave your camper packed away wet. If you

must leave a campsite with wet canvas be sure to

open and dry out your tent thoroughly at the very first

opportunity when you get home. Mould can develop in

just a couple of days so don’t take the risk.

When packing up even a dry tent it is important to check under the mattress that there is no build-up of condensation

overnight. Body heat on a mattress can create enough temperature difference with the exterior for moisture to form

under it. If left unchecked this can cause mould when your camper is stored. Bird droppings can damage your canvas

due to the Ph level. Always clean off any animal dropping as soon as possible.

When storing your camper between camping trips it is recommended you pack a couple of moisture absorber packs

into your camper. On soft floor campers these are best placed beside the mattress, on hard floor camper they should

be packed inside the main body. Using these packs is critical in tropic regions due to the humidity as when the inside

temperature of the camper drops overnight, the moist air can turn into condensation which in turn will cause mould.

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Setting up your Camper

Choosing a Spot to Set Up

When choosing a spot to set up your camper, start with a flat area with no overhanging trees. Birds and bats

occupying trees can defecate leaving droppings on your camper that can damage paint and canvas and leaves and

sap can also taint the canvas. Ensure you are not camping in an area prone to flooding or with bad drainage in the

event of rain. Even the slightest hollow in the ground can put you in a mini lake. In hot weather if possible, set your

camper up so the sun’s arc goes from front to back or back to front with the annex/awning in the general direction the

sun is arcing across. Doing this will keep the bulk of the camper in shade and the inside cooler as it will be protected

by the tropical roof and shaded by the awning.

Levelling Your Camper

The stabiliser legs on your camper/caravan are not designed for supporting the full weight of the trailer, they are there

to stabilise it once it is level. Using your stabilisers as a lifting mechanism will void your warranty as will extending

them with a “rattle gun” or “impact wrench”. Levelling front to back can be done by raising and lowering the jockey

wheel prior to adjusting the stabiliser legs. Getting the trailer level from left to right should be done with drive on

stepped ramps as illustrated below. Once levelled the legs can be lowered to keep the trailer stable. On soft ground

you may want to use timber sole boards under the stabiliser feet.

Site Power

The Projecta charger in your camper requires a 10amp power source and can be connected via an extension lead to

any 240v domestic power point. Never leave power leads coiled when in use, lay the lead out back and forward in a

manner that won’t be a trip hazard or risk damage to the lead. If the site power is not RCD protected it is

recommended to use a portable RCD device.

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Pole Diagram

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Preparing for Bad Weather

Modern camper tents are designed with a roof height to accommodate taller people. The trade off with this kind of

design is the pitch of the roof is not always steep enough for water to run off effectively in heavy rain. To better

prepare for wet conditions it is advisable in most cases to increase the pitch of the awning/annex roof by lowering the

corners furthest away from the main tent. This should be done to the degree that water cannot pool on the roof.

Additionally, in soft floor campers it is advisable to lower the back corner pole opposite the bed and furthest from the

annex to ensure water can’t pool on the main tent.

Canvas is not designed to store water. Water pooling can stretch and damage canvas and in extreme cases bend the

supporting poles of the camper. This is considered storm damage and is not covered by your camper manufacturer

under warranty.

Packing Away Your Camper

It’s vitally important when packing your camper up after use that you be mindful of the following:

• Always fully retract the steps tight against the door panel to avoid poles striking the frame when closing the

camper.

• When closing your camper, never force it. If you encounter unusual resistance, reopen, and investigate what

the obstruction is and correct it. Forcing your camper closed may result in accidental damage not covered

under your manufacturer’s warranty.

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Storage & Care

Long Term Storage

To maximise the life of your camper/caravan you should consider additional protection from the elements. UV light and

moisture can have an adverse effect on materials when left unprotected outside. This section outlines some of the

things you can do as an owner to protect your investment.

Interior

Moisture in the smallest amounts can cause mould. High humidity and cooling temperatures can create condensation,

additionally condensation can form under mattresses due to temperature differences between warm bodies on top and

the bed base being cold from outside temperatures. As a precaution you can do the following:

• Check under mattress for moisture before packing up. If moisture is found allow to thoroughly dry before

closing your camper.

• Store 1 or 2 moisture absorbing packs/dehumidifier packs in the camper/caravan to draw away any residual

water vapour.

• If packing up with damp canvas, open and dry out the camper at the first opportunity when returning home.

Dry all canvas thoroughly and follow point 2.

Exterior

Hard floor: Ensure all seals on the camper have proper compression at 30-50%, are free of dirt and have no canvas

protruding past the seals. UV light and the elements can over time cause seals and fitting to perish and become brittle.

The use of a camper cover or tarpaulin will extend the life of components and keep your investment looking better for

longer.

Securing Your Camper

When parked and unhitched you should always use suitable wheel chocks to ensure the trailer can’t move in the event

of a handbrake failure. For security a wheel clamp or and hitch lock are highly recommended.

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Torque Settings

Wheel Nuts

Wheel nuts should be tightened to correct torque using a torque wrench. Never trust a “rattle gun” as these may over

or under tighten. A quality torque wrench will ensure nuts are tightened correctly. It’s important to remember to check

your wheel nuts at 50km, 500km and 1000km and periodically thereafter. The correct torque setting of 125Nm for

12mm studs, 140nm for 14mm studs and alloy wheels and 200nm for 14mm studs with steel rims. Refer to the plate

on your drawbar.

Hitch

The high tensile bolts securing your hitch should be tightened to 76Nm. These should be checked at 5000km intervals

or 2500km in harsh off-road conditions.

Trailing Arm Pivot Bolts

The pivot bolts are a high tensile steel. The service interval for these bolts is 5000km under normal use and 2500km

for harsh off-road conditions. During travel they should be inspected daily to ensure they have not rotated or become

damaged. Correct torque is 190Nm

Brakes and Handbrake - Electric

Features

Your trailer is fitted with electric brakes that require a brake controller that can be operated from the driver’s seat.

1. Manual adjusted to provide the correct braking capability for varying road, off-road and load conditions.

2. They can be modulated to provide more or less braking force, thus easing the brake load on the towing

vehicle.

3. There is very little lag time between the moment the tow vehicle’s brakes are actuated and the moment the

trailer brakes are actuated.

4. They can provide some braking independent of the tow vehicle in the event of an emergency.

Operation

When electrical current is fed into the system by the controller, it activates the electromagnets in the brakes. These

electromagnets are energized and are attracted to the rotating surface of the drums which moves the actuating levers

in the direction that the drums are turning thus applying pressure from the brake linings to the drum surface

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Trailer Plug Wiring

The following diagrams outline the correct wiring for 7 pin plug

Hand Brake

Parking brakes are mechanically operated by cable means. The cable attachment occurs outside of the brake backing

plate. Cable force applied to the parking lever creates a torque through the pivot pin and cam assembly. Torque

transferred to the parking cam results in a spreading force between the primary and secondary shoes. The shoes in

turn, move towards the drum until contact is made. Friction generated between the drum and lining contact surface

results in parking brake capability.

Use the cable adjuster to give sufficient tension to be able to set the handbrake lever on the last two notches of the

coupling or handbrake is 1/3 raised when unladen. This needs to be checked again when the trailer or caravan is

loaded. If the cable is too tight, the brakes will be applied as the axle moves backward under spring deflection.

Adjuster

To adjust the handbrake cable tension release locknuts A, B and C in the diagram Handbrake Adjuster 1 below. To

tighten the handbrake cable turn the adjuster wheel D in a clockwise direction. Once adjusted retighten lock nuts and

test. Always ensure that wheels turn freely when handbrake is off. Overtightened cables can cause brakes to drag and

damage the brake linings.

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Correct Use of Your Electric Brakes

Your trailer brakes are designed to work in synchronisation with your tow vehicle brakes. Never use your tow vehicle

or trailer brakes alone to stop the combined load. Your trailer and tow vehicle will seldom have the correct amperage

flow to the brake magnets to give you comfortable, safe braking unless you make proper brake system adjustments.

Changing trailer load and driving conditions, as well as uneven alternator and battery output, can mean unstable

current flow to your brake magnets. It is therefore imperative that you maintain and adjust your brakes as set forth in

the controller manual, use a properly modulated brake controller and perform the synchronisation/adjustment

procedure recommended by the brake controller supplier.

Important Safety Notice

Proven and in some cases approved service methods and correct repair procedures are

essential for the safe, reliable operation of the brakes, suspension and axles as well as the

personal safety of the individual doing the work. This manual intends to provide general

directions for performing service and repair work with tested, effective techniques. By

following these guidelines, it will help assure

reliability. The numerous variations in procedures, techniques, tools and parts for servicing

axles, as well as in the skill of the individual doing the work will determine outcomes. This

manual cannot possibly anticipate all such variations nor provide advice or cautions as to each. Accordingly, anyone

who departs from the instructions provided in this manual must first establish that they neither compromise their

personal safety nor the vehicle integrity by their choice of methods, tool’s or parts.

*If at all in doubt please refer all repairs and maintenance to a suitably qualified or experienced mechanical repairer.

*Market Direct Campers accepts no liability for personal injury, loss or damage resulting from incorrect applications,

methods and failure to perform maintenance safely and correctly.

Brake Adjustment

Brakes should be adjusted (1) after the first 300 km’s of operation when the brake shoes and drums have “seated,” (2)

at 5000 km’s intervals, (3) or as use and performance requires. The brakes should be adjusted in the following

manner:

Never crawl under your trailer unless it is resting on properly placed jack stands. Do not

place supports on any part of the suspension system and use the designated jack point or

under the spring base plate to jack trailer.

Brake Cleaning and Inspection

Your trailer brakes must be inspected and serviced at 5000km or more often as required by use and performance.

Magnets and shoes must be changed when they become worn or scored to avoid inefficient vehicle braking.

Brake Lubrication

This should only be done by qualified persons.

Caution

Do not get grease or oil on the brake linings, drums or magnets.

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MDC XH7.4 XPEDITION HAULER Owner's manual

Brand: MDC

Model: XH7.4 XPEDITION HAULER

Type: Owner's manual

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MDC XH7.4 XPEDITION HAULER Owner's manual

MDC XH7.4 XPEDITION HAULER Owner's manual

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